Cyclic control



Patented Nov. 8, 1949 UNITED STATES PATENT OFFICE tion of Delaware Application April 29, 194s, serial No. 24,03

7 Claims.

The invention relates to a cycle controller and while not limited thereto is particularly applicable to electric resistance welding systems.

The invention is an improvement of the cycle controller disclosed and claimed in my applicationY Serial Number 742,639, filed April 19,1947, now Patent No. 2,476,882.

In the aforementioned application a system was disclosed which affords cyclic operation in a series of successive steps, the order of succession of such steps being fixed but the time intervals between steps being adjustable. In the present system the order of succession of such steps may be preserved while an early step may be optionally varied in characteristics as by repetition to aiord different pre-selected programs of operation. Thus when employed for electric resistance weldingA it is possible, after the parts to be welded are forced into intimate contact with each other, to supply to the weld a number of accurately measured welding current pulses interspersed by timed periods when no current iiows to afford a certain amount of intermediate cooling of the weld. During such cooling periods the initial pressure applied to the weld isl maintained.

Another object of the present invention is to provide in a welding" controller' o'the like accurate in dependent' adjustment of the several t'iine intervals of a cycle of operation'.

Another object is to provide a cycle controller in which certain steps of the cycle may be repeated a varying number of times during a' single cycleas may be` preselected.

Another object is to provide a cycle controller which aiiords division of the time period of a given step into a selected number of fractional periods each of preselected duration;

Other objects andk advantages of the invention will hereinafter appear.

The accompanying drawing is illustrative of I an embodiment of the invention. In the drawa ing,

Figure 1 is a diagram of connections of the various parts of the system, while Fig. 2 shows diagrammatically' the mechanical relationship of the various elementsof the system illustrated in Fig. 1;

Referring to the drawing, a hydraulic welding machine is represented by a cylinder I having a piston II, to which is attached one electrode I2 connected to one terminal of a secondary winding I3a of a welding transformer I3 having a primary Winding I`3b. The second terminal ofthe winding I3#is'connectedv t'o a sta- 2 tionary anvil or electrode III of the welding ma` chine. The parts to be welded together are introduced between the jaws I 2 and I 4 so that when the jaws are pressed together and the trans'- former I3 is energized, welding current passes between the jaws and through the parts to be Welded to heat the parts to welding temperature.

The cylinder Ill is supplied with actuating pressure uid from any convenient source through a normally closed valve I 5El having an electromagnetic operating winding I5b, which when en' ergized opens the valve` I5a to admit pressure fluid to the cylinder I0. The pressure cylinder is also provided with a pressure responsive relay Ia. which as indicated in Fig. 2 is provided with normally open contacts I6". The winding I5b is supplied with energy from alternating current bus bars L1, L2, ina manner which will be described hereinafter.A

Connected between the lines L1, L2, and in series with transformer winding I3b in inverse parallel with each other are the ignitrons I1 and I8. The'ignition electrode I8 of ignitron I8 is connected through two half wave rectiiiers 20a and 20h to the anode of ignitron I'I, and the ignition 4electrode* IIa of ignitron I7 is similarly connected through two half wave rectiers I9a and I9b to the anode of ignitron I8. There' is also'connected across lines'Ll, L2 a primary winding 2la ofV` a transformer 2I, which has a sec'- onclary" winding 2I'b provided with an intermedie ate current tap. One endr terminal ofthe wind-- ing 2|b is connected to a' bus bar 22.- The inter-V mediate tapl is connected through a resistor 23 tov a busbar 25a; While'theotl'le'r end terminal1 of the winding- 2lb isv connected through normally disengaged contacts 5I!b to a bus bar 2'4. The intermediate tap of thewinding 2`Ib isl also connected directly toa bus bar 25.

The'syst'em further' includes the following elec-y tro-magnetic relays: relay 46' having' anentiere4 gi'zin'gV winding' 46a, normally open contacts' 465 and normally closed contacts 46c and 46d; relay 41, having a winding 1Her and normally closed' contacts Wbv and.y 41d; relay'll'having a Winding 48a, and normally closed contacts 4'81" and* 48e; relay 4o, havinga winding 49a, and normally closed contactsv 495; relay 50 having a Winding 50a, normallyv open contacts 5I'Iby and normally closed contacts suf; relay 55. having" a winding a, normally open contacts 55' and' 55d; relay Connected to the bus bar 22 are the cathodes f gaseous tubes 26, 21, 28, 29, |28 and |29, respectively. Connected in parallel with one another across the bus bars 22 and 25a are potentiometer resistors 30, 3|, 32, 33, |32 and |33, respectively. The movable contacts of said resistors are connected in series with adjustable capacitors 34, 35, 36, 31, |36 and |31, respectively, and cun'ent limiting resistors 38, 39, 40, 4I, |40 and |4I, respectively, to the control electrodes of the tubes 26, 21, 28, 29, |28 and |29, respectively. The capacitors are paralleled by discharge resistors 42, 43, 44, 45, |44 and |45, respectively. The anodes of the aforementioned tubes are each connected to one of the terminals of the energizing windings 46, 41, 48a, 49a, |41 and |48, respectively. Each of the foregoing windings is preferably paralleled by a smoothing capacitor. The second terminal of winding 46a is connected through normally open contacts I6b to the bus bar 24. The common points of resistors 42 and 38, resistors 43 and 39, resistors 44 and 40, resistors 45 and 4|, |44 and |40, |45 and I4I are connected through normally closed contacts 50, 46, 41, 48, 46d and I41, respectively, and in series with half wave rectiers 52, 53, 54, |53 and |54, respectively, to the bus bar 25.

The windings 50L and 55a are connected in parallel with one another and in series with contacts 55b and 49b across the lines L1 and L2. A double throw single pole switch 56 when in one position connects a normally open push button switch 51 in parallel with the contacts 55h, while in the other position it connects the push button switch 51 in parallel with both contacts 55b and 49h.

The operation of the system thus far described is as follows: Let it be assumed that it is desired to produce a single welding current impulse. It is to be observed that with the lines L1, L2 energized the capacitors 34 to 31, |36 and |31 are charged to block conduction of the respective tubes. With switch 58 closed the switch 56 is moved to the position shown in the drawing and the push button switch 51 is closed. This energizes coils 50a and 55a, thereby closing contacts 55, 55d and 50h, and opening contacts 50. This in turn energizes valve solenoid I5b to open valve I5 and admit pressure uid to cylinder II to move electrode I2 towards the workpiece I4. When the electrode I2 exerts pressure on the workpiece and the pressure of the cylinder I0 reaches the desired value, the pressure relay I6a closes contacts IGb. Closure of contacts 55b provides a maintaining circuit for coils 50a and 55a through the contacts 55b and 49b in parallel with the push button switch 51 which may now be released.

Opening of contacts 50 opens the charging circuit for capacitor 34, and the latter gradually discharges through resistor 42. After a time interval the potential of the grid of tube 26 has been reduced so as to permit conduction of said tube. It will be observed that the voltage which is impressed on the control electrode of tube 26 consists of a unidirectional voltage component impressed thereupon by the capacitor 34 and an alternating potential derived from the potentiometer resistor 30. It will also be observed that the alternating potential is substantially in phase with the potential impressed upon the main electrodes of the tube 26. As a result the rate of change of the resultant voltage impressed upon the aforementioned control electrode at the moment it passes through the critical voltage value at which the tube 26 becomes conducting, is relatively high even though the rate of change of the capacitor voltage is relatively low, thus affording a very precise control of the instant at which the tube 26 becomes conducting during the positive half cycle of the voltage impressed thereon. The same observation also holds true for the operation of the other tubes 21 to 29, inclusive, |28 and |29. As soon as tube 26 conducts the coil 46 is energized to close contacts 46, which completes the circuit for energizing the ignition electrodes I1a and I8a so that tubes I1 and I8 conduct current through the primary winding |38, which causes supply of welding current to the work. Energization of coil 46a also opens contaots 46 and 46d. This causes capacitor 35 to discharge to unblock after a time interval tube 21 and thereby energize coil 41. Opening of contact 46d effects discharge of capacitor |36 which after a time interval causes energization of electromagnet |41a, such energization eiiecting in turn opening of contacts |41b and |41. Opening of contacts |41b interrupts supply of ignition potential to tubes I1 and I8 and thus interruption of welding current, while relays 46 and 41 remain energized. Opening of contacts |41c causes after a time interval energization of relay |48 which closes contacts |48b and opens contacts |48. If relay 41 is energized at this moment, contact 41h is open, and as contact 46d is also open, the tube |28 remains unblocked and relay |41 remains energized, keeping contacts |41b and |41 open. This after a time interval causes in the manner described for the other tubes and coils energization of coil |48 and closure of contact |4811, and opening of contact I48. As a result tube 28 is unblocked after a time interval and coil 48 is energized, opening contact 48b to deenergize the magnet I5", and after the pressure in the cylinder I0 has decreased the contacts I6h are opened to interrupt current supply to tube 26. This interposes a second gap in the ignition circuit of tubes I1 and 8. Contacts 48c are also opened, thus unblockng tube 29 to energize relay 49 which opens maintaining contacts 49b for the coils 50 and 55, returning the system to initial conditions.

When adjusted as described so far a single welding current pulse is obtained upon each depression and release of the push button switch 51. If it is desired to obtain repeated cyclic operation of the system as long as push button switch 51 is closed, the switch 56 is moved to its lower position, and the push button switch 51 is thus connected in series with contacts 49. Hence after deenergization of relay 49 upon completion of a cycle, contacts 491 are reclosed and as long as push button switch 51 is held closed the entire cycle as described will be repeated.

If it is desired to obtain an intermittent supply of welding current with interspersed cooling periods during a complete operating cycle, the period required to discharge the capacitor 35 to a potential which permits conduction of tube 21 is adjusted so that it is several times the discharge period of capacitors |36 and |31. Hence when contacts 46 and 46d are opened and 46b is closed upon energization of relay 46 to cause now of welding current, the tube |28 becomes conducting after a time interval and relay |41 is energized. The Welding current is interrupted by opening of contacts |41". Shortly thereafter relay I48 is energized, as contacts |41c also open. This closes contacts |48", and as contacts 41b are still closed, the contacts 46d are paralleled and the capacitor |36 is charged to block tube |28 and deenergize relay |41, again closing the ignition circuit for tubes |1 and I8 by closure of contacts |41". This again causes flow of Welding current. Deenergization of relay |41 causes contacts |41c to close and capacitor |31 is charged to block tube |29 which deenergizes relay |48.

Contacts |481 are opened again, and after a time interval relay |41 is reenergized and contacts |41c are opened, thus again reenergizing relay |48 after a time interval. The alternate energization of relays |41 and |48 and the resulting alternate supply and interruption of welding current is repeated until capacitor 35 is suiciently discharged to permit energization of relay 41. Upon such energization contacts 41b are opened and this prevents further energization of relays |41 and |48, whereupon relays 48 and 49 are successively energized and the cycle is completed as already described. It should be pointed out that depending upon the relative adjustment of the several discharge circuits the relay 41 may be energized so that the last period of energization of relay |41 will be a fraction of the period of relay |41 preset by its own turning means, thus affording a ne gradation of the last period of flow of welding current.

The aforedescribed alternation between heating and cooling may be employed either for a single cycle setting or for repetitive cycle setting of the switch 56. In either case the contacts 41 open to effect energization of relay 48 to complete the welding cycle as described. Thus it is possible to obtain several complete current pulses or several complete and a nal fractional current pulse during a cycle of intermittent heating and cooling operation.

I claim:

1. The combination with an alternating current source, of a plurality of electroresponsive windings, a like number of grid type electron tubes individualized to said windings and interposed between the same and said source, individual grid circuits for said tubes supplied from said source and comprising capacitors which when charged block discharge of said tubes thereby to deenergize said windings, a translating circuit, and contacts operable by said vwindings including control contacts for said translating circuit and also contacts for controlling charging and discharging of said capacitors, certain of said grid circuits being adjustable in respect of time required for capacitor discharge to render selective different predetermined cycles of control of said windings, one such cycle being characterized by completion of said translating circuit for a single period of limited duration, and another such cycle being characterized by completion of said translating circuit for successive periods of limited number.

2. The combination with an alternating current source, of a plurality of electroresponsive windings, a like plurality of grid type electron tubes individualized to said windings and interposed between the same and said source, individual grid circuits for said tubes supplied from said source and comprising capacitors which when charged block discharge of said tubes thereby to deenergize said windings, a translating circuit, and contacts operable by said windings including 4control contacts forl said translating circuit and also contacts for controlling charging and discharging of 'said capacitors, certain of said grid circuits being adjustable in respect of time required for capacitor discharge, to render selective different predetermined. cycles of con. trol of said windings, one such cycle being characterized by completion of said translating circuit for a single period of limited duration, and another such cycle being characterized by completion of said translating circuit for successive periods of limited duration and limited number, iinal interruption of said translating circuit being in both instances a function of response of a given one of said windings.

3. The combination with an alternating current source, of a plurality of electroresponsive windings, a like plurality of grid type electron tubes individualized to said windings and interposed between the same and said source, indi,- vidual grid circuits for said tubes supplied from said source and comprising capacitors which when charged block discharge of said tubes thereby to deenergize said windings, a translating circuit, and contacts operable by said windings including control contacts for said translating circuit and also contacts for controlling charging and discharging of said capacitors, certain of said grid circuits being adjustable in respect of time required for capacitor discharge to render selective different predetermined cycles of control of said windings, one such cycle having an early step thereof characterized by completion of said translating circuit for a single period of limited duration and another such cycle having such early step thereof characterized by completion of said translating circuit for successive periods of limited duration and limited number, nal interruption of said translating circuit being in both instances a function of response of a given one of said windings as is also initiation of a following step common to both cycles.

4. The combination with an alternating current source, of a plurality of electroresponsive windings, a like number of grid type electron tubes individualized to said windings and interposed between the same and said source, individual grid circuits for said tubes supplied from said source and each comprising a rectier, a capacitor which when charged blocks discharge of the respective tube thereby to deenergize the respective winding, and individual discharge resistors connected across said capacitors tending to discharge the same, a translating circuit, and contacts operable by said windings including control contacts for said translating circuit and also contacts for controlling charging and discharging of said capacitors, certain of said grid circuits being adjustable in respect of time required for capacitor discharge, to different predetermined cycles of control of said windings selectively, one such cycle being characterized by completion of said translating circuit for av single period of limited duration, and another such cycle being characterized by completion of said translating circuit for successive periods of limited duration and limited number.

5. The combination with an alternating current source, of a plurality of electroresponsive windings, a like number of grid type electron tubes individualized to said windings and interposed between the same and said source, individual grid circuits for said tubes supplied from said source and each comprising a rectier, a capacitor which when charged blocks discharge of the respective tube thereby to deenergize the respective winding and individual discharge resistors connected across said capacitors tending to discharge same, a translating circuit, and contacts operable by said windings including control contacts for said translating circuit and also contacts for controlling charging and discharging of said capacitors, certain of said grid circuits being adjustable in respect of time required for capacitor discharge, for affording different predetermined cycles of control of said windings selectively, one such cycle being characterized by completion of said translating circuit Afor a single period of limited duration, and another such cycle being characterized by completion of said translating circuit for successive periods of limited duration and limited number, iinal interruption of said translating circuit being in both instances a function of response of a given one of said windings.

6. The combination with an alternating current source, of a plurality of electroresponsive windings, a like number of grid type electron tubes individualized to said windings and interposed between the same and said source, individual grid circuits for said tubes supplied from said source and comprising rectiers, capacitors which when charged block discharge of said tube, thereby to deenergize said windings, and individual discharge resistors connected across said capacitors tending to discharge same, a translating circuit, and contacts operable by said windings including control contacts for said translating circuit and also contacts for controlling charging and discharging of said capacitors, certain of said grid circuits being adjustable in respect of time required for capacitor discharge to render selective different predetermined cycles of control of said windings, one such cycle having an early step thereof characterized by completion of said translating circuit for a single period of limited duration and another such cycle having such early step thereof characterized by completion of said translating circuit for successive periods of limited duration and limited number, iinal interruption of said translating circuit being in both instances a function of response of a given one of said windings as is also initiation of a following step common to both cycles.

'7. A cyclic controller operable When supplied with alternating current to perform a given function for a single period of limited duration, or alternatively for a limited number of successive periods each of given duration, comprising in combination, iirst, second and third electroresponsive windings, grid type electron tubes individualized to said windings to conduct current thereto from an alternating current source, individual grid circuits for said tubes, each of said circuits to be subjected to an alternating potential and each including a capacitor, a discharge resistor connected across said capacitor and a rectier in the charging connection for said capacitor, and automatically operating contacts to make and break the charging connections of said capacitors, said contacts, of which certain are operable by said windings, being effective according to adjustment of said grid circuits in respect of time required for discharge of their said capacitors, to cause said tubes to energize said three windings in a given order and only once or alternatively to energize said second and third windings sequentially and repeatedly pending energization of said first Winding and to energize said iirst winding subject to a given time delay thereby to stop repetition of energization of said second and third windings.

GEORGE J. LEXA.

REFERENCES CITED The following references are of record in the le of this patent:

UNITED STATES PATENTS Number Name Date 2,372,129 Smith Mar. 20, 1945 2,390,982 Bivens Dec. 18, 1945 2,415,396 Undy Feb. 4, 1947 2,421,994 Cooper June 10, 1947 

